Package for plastic refractory material



Dec. 11, 1934. J. E. ANDERSON 1,983,590

PACKAGE FOR PLASTIC REFRACTORY MATERIAL Original Filed Aug. 8, 19 32 toshape and then tamp them together.

Patented Dec. 11, 1934 UNITED STATES lA'lENT OFFICE John E. Anderson,Chicago, IlL, assig'nor to Plibrico Jointless Flrebrlck Company,Chicago, 11]., a corporation of Illinois Original application August a,1932. Serial No. r 627,853. Divided and, this application November 10,1833, Serial No. 697,451

5 Claims.

The present invention relates to the prepara: tion and packaging ofplastic refractory material in such manner that its transportation toand application in furnace constructions, fire resisting walls, linings,arches and the like is facilitated, eliminating undue labor cost andexcessive handling, as well as increasing the effective application ofthe material to such constructions.

The subject matter of the present invention is a division of the subjectmatter disclosed in my copending application, Serial No. 627,853, filedAugust 8, 1932.

Plastic refractory material has come into general use for liningfurnaces, arches and the like. As heretofore supplied, this material hasbeen packaged in bulk in a metallic container or drum. The drum issubstantially air-tight and moisture tight, and it tends to maintain thematerial in a suitable plastic condition for application to the wall orsurface to which it is to be applied. If such material is exposed toair, it may dry out to such an extent that it is not suitable forapplication, and does not produce an effective lining.

The handling of these drums with a relatively large mass of refractorymaterial therein is difiicult because of the weight and size of thesame, and in order to apply the plastic from the drum to the job, it isnecessary that the mass be cut or broken into pieces small enough to bereadily handled and applied. The material is of a thickness such as torequire tamping to bond the detached pieces together to form amonolithic linmg.

In the prior practice, it has been necessary to cut or break the massfrom the drums into suitable pieces or chunks, apply these to the wall,and The irregular size of the pieces, as broken from the mass, increasesthe time necessary to fit the pieces properly into the lining, andfurther, does not produce an effective substantially homogeneous liningwithout excessive tamping and the like.

I have conceived the desirability of preforming the plastic materialinto sizes and shapes suitable for direct application to a wall and toeach other, and delivering these in suitable condition directly to theuser. The advantages gained by this procedure are striking. By formingrectangular slabs of suitable dimensions, for example, 2" by 9" by 121',these slabs can be applied directly to the wall and tamped into bondingengagement successively without the necessity for shaping or cutting theplastic material from a large unwieldy mass. The building of the wallcan be performed more expeditiously and efiiciently by the use ofpreformed slabs, the material can be handled to better advantage, and amore uniform application is possible. In order to deliver the slabs tothe user at the place of use in proper condition for immediateapplication, I have conceived the desirability of assembling in arelatively small stack or pile a number of these slabs to form a 1suitable package that can be conveniently carried by a workman, and canconveniently be passed through a firebox door or the like, and deliveredat the spot where the wall or lining is being constructed.

The delivery of these slabs without adverse change in their plasticityor moisture content, and without change or deformation in shape, isaccomplished, according to my invention, by immediately sealing theslabs in a substantially air and moisture tight wrapper after theformation thereof, and supporting the same ina rectangular box closelyfitting the pile of slabs and conforming to the periphery of the stack.The slabs, because of their relatively largesurface area as compared totheir volume, are subject to drying on the surfaces, and hence lose someof their bonding characteristics when they are stacked, thus eliminatingdanger of bonding during stacking. After the moisture retaining wrapperhas been placed about them, the moisture content in the central portionof each slab tends to work toward the surface of the slab.- Since thewrapper prevents evaporation of moisture from the stack, a condition ofequilibrium is reached, with the slabs having a uniform moisture contentthroughout the stack. Bonding at this time is prevented because there isno manipulation of the slabs and no pressure on them, as they areenclosed within the carton. In this manner, the slabs are brought to theproper condition for application, having a maximum plasticity'for agiven moisture content. The rectangular containing box which fits thepile of slabs quite closely holds them in shape, and preventsdeformation. The pile is made small enough so that the slabs do not bondtogether by pressure in the package during handling or when allowed tostand for a period of time, which might occur with relatively largestacks or piles, and the package is, at the same time, in the preferredform of the invention, of not excessive weight for a single workman tohandle expeditiously. The slabs are preferably so stacked as to supporttheir own weight independently of the other slabs in the stack, toprevent any possibility of bonding due to pressure when a large numberof packages are stacked in a warehouse or the like.

The box or outer enveloping member may be a stiff fiber board or similarcarton, and the package is relatively inexpensive, the container beingdestroyed readily as the package is opened, or being retained and usedfor future packaging.

Heretofore, where the plastic refractory material has been shipped to adesired location in a sheet metal container, such as a drum or the like,extra labor and handling has been required because of the size of thefirebox opening, which may be too small to accommodate such a drum.Also, the weight of such a container filled with the plastic is such asto make it inconvenient and undesirable to move the container bodilyinto the firebox even if the opening is large enough to accommodate it.In such instances, it has been necessary to break the drum open outsideof the fire-box, cut the material into suitable slabs or pieces, andpass them to the workmen within the enclosure thru the fireboxopening.This consumes considerable time and extra labor, in that the chunks orbroken pieces must be fitted, and must be thoroughly tamped in order toprovide an effective lining or the like.

According to my invention, the package itself is passed into the fireboxor other enclosure, and the preformed slabs are taken from the packageand applied directly to the wall with minimum handling and breakage, andwith a maximum of convenience and ease in applying the material andtamping the same to bond, as well as providing an effective refractorystructure, having the characteristics of'a monolithic lining. Thewrapper which surrounds the slabs can be spread out within the fireboxand so used as a sort of working table, preventing the slabs from cominginto contact with dirt, ashes or debris which may be within the firebox.

In order to acquaint those skilled in the art with the manner ofpracticing my invention, I shall describe, in connection with theaccompanying drawing, a specific embodiment of the same.

Figure l diagrammatically illustrates the extrusion of a stream of theplastic refractory material after it has been suitably tempered, andalso illustrates the cutting of the slabs from the stream;

Figure 2 illustrates the piling together of a number of these slabs incontact with each other, preparatory to wrapping them in a moistureretaining wrapper;

Figure 3 shows the group or" slabs, for example, six in number; enclosedwithin the moisture retaining wrapper;

Figure 4 is a perspective view or"- the finished package or carton readyfor shipment and delivery to the user; and

Figure .5 shows the method of application of a slab in forming a wall orlining for the furnace, and also illustrates the manner in which thecartons are handled and utilized in practicing the invention. I

Referring now to the drawing in detail, Figure 1 shows an auger mill 1,which is of any suitable type for extruding a stream 2 of the plasticrefractory therefrom. This plastic refractory is first kneaded andtempered in a pug mill or other suitable means to form a stiff,substantially homogeneous plastic mass. Ihe stream 2 is squirted outupon a conveyor or belt 3, and is cut off into slabs 4, such cuttingoperation being illustrated at 5. While I have shown the slabs as beingcut off one at a time, as the stream issues from the mill, it is to beunderstood that by the use of any special wire cutting machine, two ormore slabs may be cut at a time. The extrusion and cutting of a streamof plastic is well known, in a general way, and follows the practice inthe brick industry to which reference is hereto made. In the operationillustrated the conveyor 3 preferably runs faster than the stream 2 inorder to separate the individual slabs.

The slabs 4 are of a suitable thickness to adapt them to be tampedtogether for bonding purposes, as will be explained later. I have foundthat a suitable dimension for a material such as is used in making firebrick or refractory lining to be two inches in thickness. I do notintend however, to be limited to this dimension, but mention the same asa suitable dimension to be employed in the practice of the invention.The slabs 4 are substantially rectangular inform, being cut from arectangular stream 2, and their lateral dimensions are, for example, 9"by 12". These dimensions, obviously, may be varied if desired. The slabs4 are substantially self-sustaining, being of a plasticity approximatelylike a green stiff mud brick before drying. These slabs are taken fromthe conveyor and are set together on edge, as shown in Figure 2, upon asheet of moisture retaining paper, for example, oiled paper, vegetableparchment, or the like. This prevents any bonding due to pressure, whichmight occur if they were stacked vertically. The sheet 6 is large enoughto fold over and form a substantially moisture and air tight wrapperabout the mass or pile 7 of slabs, which are preferably set upon one oftheir lateral edges, with their faces abutting. As shown in Figure 2,six slabshave thus been piled together or stacked to form a suitablesized package, and they weigh, when of the dimensions above given,approximately 100 pounds. This forms a package which is of a convenientsize for handling. It is small enough to be passed through a furnacedoor or the like, and is not too heavy to be handled expeditiously byindividual workmen.

In Figure 3 I have shown the moisture retaining wrapper folded in placein close contact with the pile of slabs 4, and this wrapper is held infolded position by means of a flat metal strap, a

binder, or band indicated at 8, which is passed around the mass 7 ofslabs in such a direction as to hold them together, and also in such a.direction as to hold the folded ends of the moisture retaining wrapper6. The wrapper 6 is applied and folded in such a. manner as to bring thejoint between the edges 9, 9 of the wrapper 6 transversely of the slabs4, and lengthwise of the strap or band 3. This brings the folded ends ofthe wrapper 6 under the band 8, as is clearly shown in Figure 3.

The package thus formed and shown in Figure 3 is then disposed in arectangular box or carton which may be formed of stiff fiber board,corrugated board, or the like, which may be suitably stapled orotherwise secured in position, to give a support to .the package 10 onall sides. Box 12 may be formed of any other material suitable forclosely fitting the package 10, and retaining the shape thereof. The box12 with the package therein is closed, and is retained in closedposition by means of two crossed straps or bands of metal 13 and 14, orany other suitable closure means. The package is then shipped to theuser.

While in storage and in transit, the retention of the slabs within themoisture proof or moisture retaining wrapper 6 serves a highly usefulpurpose in permitting a thorough diffusion of moisture throughout theblocks or slabs 4 to give them maximum plasticity without increasingtheir moisture content. When the package is delivered at the place offorming the wall it is opened. The box or carton is removed, or may bemerely torn apart, and the slabs or blocks 4 are retained upon themoisture retaining wrapper 6, which is folded out as shown in Figure 5,at the place where the slabs are to be applied, thereby avoidingexcessive handling and avoiding breakage. Also, by unfolding the wrapper6, a suitable working surface, clear of debris, dirt and the like isformed. The blocks 4 are then laid one at a time and tamped down tobond, as by means of the mallet 15 or any other suitable tamplng tool.The slabs are thereby bonded by tamping to form a solid wall 16, whichmay be a lining for the inside of a furnace wall, such as the wall 17.Obviously, instead of being built into a flat, vertical wall, theseslabs may be built into an arch or any other shape desired.

It will be noted, in Figure 5, that I have shown I one of the packagesopened. and the wrapper thereof spread out to form a sort of workingtable upon which the slabs 4 are positioned. At the same time, acompletely closed and banded carton 12 is shown as being passed throughthe relatively small opening into the firebox. It is apparent that itwould be inconvenient to pass the plastic material within a metallicdrum or similar container through such an opening, because of its sizeand relative weight. It would be necessary, in this case, to open thedrum and break out the material in the form of chunks or blocks whichwould then have to be named through the opening to the workmen withinthe furnace. By providing the package of the present invention, thisextra handling and labor is eliminated, and the workmen canexpeditiously handle the package and open it as needed without requiringadditional help.

After the wall or furnace lining is formed, it is, of course, subjectedto the heat of the furnace,

as such heat of the furnace fires and hardenethe same. Due to theuniformity of the slabs before they are applied, and the tendency toequalize the plasticity and moisture content thereof while in thepackage, and due to the fact that they are tamped together in amonolithic structure, the firing of the wall or lining, and the burningor hardening of the same is accomplished with minimum cracking orchecking. The slabs form an efiective means for applying such a liningto a wall or construction or the like, and facilitate the production ofa monolithic homogeneous wall or structure.

I do not intend to limit my invention to the exact type of package shownand described in connection with the disclosure of the present invention, since I am aware that numerous changes and modifications may bemade therein without departing from the spirit of the invention, and Itherefore intend to be limited only as defined by the appended claims.

I claim:

l. A package for the transportation from the mill to the place of usefor the building of a monolithic wall of predetermined thickness, ofpreformed rectangular plastic refractory slabs which as they come fromthe mill are of the proper shape and of a size which provides a suitabledimension for controlling the thickness of the wallto be formed, andcontain a suitable average moisture content low enough to keep them frombonding by contact but great enough to permit-bonding by tamping whenproperly diffused, and wherein the moisture content is irregularlydistributed and insufliciently diffused whereby bonding by tamplng isdifllcult, said package comprising an assembly of a relatively smallnumber of slabs as they come from the mill, and a moisture retainingenvelope enclosing said assembly of slabs, and a form retaining boxenclosing the assembly and envelope, said box protesting-the envelopefrom injury and holding the assembly in rectangular form, the slabs insaid package when delivered to the user having the moisture contentthereof thoroughly equalized and diffused to improve the plasticity ofthe material and to facilitate bonding of the slabs together by tampinginto a monolithic wall.

2. A package of plastic refractory which has been tempered and worked ina mill before packaging, said package comprising anassembly of flatrectangular slabs, approximately six in num ber, of substantially thesame size, 1. e., approximately 2" x 9" x 12", said dimensions beingsuitable to control the thickness of the wall to be formed, the moisturecontent being so low that the slabs will not bond together in thepackage by mere contact, a moisture retaining wrapper enclosing saidassembly of slabs, and a readily de-= structible form ,.retainingrectangular box enclosing the assembly and 'wrapmr, said refractory,when delivered to the user, having the moisture content of the slabsthoroughly equalized and diffused to improve the plasticity of thematerial and to facilitate bonding of the slabs together by tamping whenthe package is opened.

3. The method of producing plastic refractory suitable for tamping intoa monolithic wall which comprises tempering the raw refractory materialto provide a suitable average moisture content which is too low forbonding by contact, milling and extruding the plastic in a rectangularstream, cutting the stream into slabs, said slabs being of a sizeproviding a dimension suitable for controlling the thickness of the wallto be formed having on the average a suitable moisture content butindividually varying as to moisture content and said moisture beingimperfectly difiused in the individual slabs, assembling a plurality ofthe slabs in the aforesaid condition and confining the assembled slabsina moistureproof wrapper in moisture interchanging relation to eachother, the slabs within said wrapper having their moisture contentsequalized and the moisture being thoroughly diffused throughout saidslabs to give them improved plasticity.

4; 'Ijhe method of producing plastic refractory suitable for tampinginto a monolithic wall, which comprises tempering the raw refractorymaterial to provide a suitable average moisture content which is too lowfor bonding by contact, milling and extruding the plastic in arectangular stream, cutting the stream into slabs, said slabs being of asize providing a dimension suitable for controlling the thickness of thewall to be formed having on the average a suitable moisture content butindividually varying as to moisture content and said moisture beingimperfectly diffused in the individual slabs, assembling a plurality ofthe slabs in the aforesaid condition and confining. the assembled slabsin a moistureproof wrapper in moisture interchanging relation to eachother, the slabs within said wrapper having their moisture contentsequalized and the moisture being thoroughly diffused throughout saidslabs to give them improved plasticity, and transporting said slabs insaid confinement, and without bonding, to the place of use.

in which they come from the forming operations, and then confining theassembledslabs in a moisture retaining wrapper in such relation to eachother that the moisture content is substantially equalized betweenslabs, and the moisture of each slab is thoroughly diffused throughoutits body to give it maximum plasticity.

JOHN E. ANDERSON.

